Apparatus and methods for providing controlled shapes during stamping process of computer system enclosures

ABSTRACT

Disclosed are novel methods and apparatus for provision of controlled shapes during the stamping process of sheet metal, for example, used as a computer system enclosure. In accordance with an embodiment of the present invention, a method of providing an irregular shape on a computer panel is disclosed. The method includes: creating a plurality of openings in the computer panel, the plurality of openings tracing a pattern that forms the irregular shape, each of the plurality of openings having a substantially straight edge adjacent to the pattern; and applying force onto the computer panel along the plurality of openings to provide the irregular shape without warping or twisting the computer panel.

FIELD OF INVENTION

[0001] The present invention generally relates to the field of computer system design. More specifically, an embodiment of the present invention relates to a method of providing controlled shapes during the stamping process of a computer system housing.

BACKGROUND OF INVENTION

[0002] As integrated circuit fabrication technology improves, manufacturers are able to integrate additional functionality onto a single silicon substrate. As the number of these functionalities increases, however, so does the number of components on a single chip. Additional components add additional signal switching, in turn, creating more heat. The additional heat may damage a chip by, for example, thermal expansion. Also, the additional heat may limit the locations where a computer system may be installed. For example, if a computer is to be used in the same vicinity as a computer user (e.g., as a desktop computer), industry standard environmental controls such as those used in data centers (sometimes costing millions of dollar are impractical.

[0003] Accordingly, heat dissipation is one of the most important challenges facing the computer industry today in light of the growing need for computer speed and functionality. It is expected that within a few years, processors may be consuming more than one thousand (1,000) Watts of power. In response, numerous techniques are currently utilized by computer manufacturers to reduce the affects of this problem.

[0004] One common way to flush out the heat is through utilization of fans in conjunction with heat sinks. Heat sinks are generally pieces of metallic material that pull the generated heat away from a chip. The fans then direct the extracted heat outside of the computer system. Most of today's computer systems utilize a metallic enclosure to provide structural rigidity, efficient thermal exchange, and an electrically grounded enclosure for the facet of electronic devices inside the computer system. Such a metallic enclosure is often made from a flat sheet metal, which is mechanically stamped to obtain a desired enclosure. Most of the stamping products, however, avoid irregular shapes, in part, because stamping irregular shapes into the flat sheet metal often causes twisting and warping of the sheet metal.

SUMMARY OF INVENTION

[0005] The present invention, which may be implemented in a general-purpose digital computer, in certain embodiments, includes novel methods and apparatus to provide controlled shapes during the stamping process of sheet metal, for example, used as a computer system enclosure. In accordance with an embodiment of the present invention, a method of providing an irregular shape on a computer panel is disclosed. The method includes: providing the computer panel; creating a plurality of openings in the computer panel, the plurality of openings tracing a pattern that forms the irregular shape, each of the plurality of openings having a substantially straight edge adjacent to the pattern; and applying force onto the computer panel along the plurality of openings to provide the irregular shape.

[0006] In another embodiment of the present invention, the irregular shape may form a logo and/or a channel for airflow.

[0007] In a further embodiment of the present invention, the substantially straight edge may have a curvature following a same curvature of the pattern.

BRIEF DESCRIPTION OF DRAWINGS

[0008] The present invention may be better understood and its numerous objects, features, and advantages made apparent to those skilled in the art by reference to the accompanying drawings in which:

[0009]FIG. 1 illustrates an exemplary computer system 100 in which certain embodiments of the present invention may be implemented;

[0010]FIG. 2 illustrates an exemplary partial exploded view of a computer system 200 in accordance with an embodiment of the present invention;

[0011]FIG. 3 illustrates an exemplary top view of a side panel 300 in accordance with an embodiment of the present invention; and

[0012]FIG. 4 illustrates an exemplary side view of a side panel 400 in accordance with an embodiment of the present invention.

[0013] The use of the same reference symbols in different drawings indicates similar or identical items.

DETAILED DESCRIPTION

[0014] In the following description, numerous details are set forth. It will be apparent, however, to one skilled in the art that embodiments of the present invention may be practiced without these specific details. In other instances, well-known structures, devices, and techniques have not been shown in detail, in order to avoid obscuring the understanding of the description. The description is thus to be regarded as illustrative instead of limiting.

[0015] Reference in the specification to “one embodiment” or “an embodiment” is intended to indicate that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least an embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

[0016]FIG. 1 illustrates an exemplary computer system 100 in which certain embodiments of the present invention may be implemented. The system 100 comprises a central processor 102 (or central processing unit (CPU)), a main memory 104, an input/output (I/O) controller 106, a keyboard 108, a pointing device 110 (e.g., mouse, track ball, pen device, or the like), a display device 112, a mass storage 114 (e.g., a nonvolatile storage such as a hard disk, an optical drive, and the like), and a network interface 118. Additional input/output devices, such as a printing device 116, may be included in the system 100 as desired. As illustrated, the various components of the system 100 communicate through a system bus 120 or similar architecture.

[0017] In accordance with an embodiment of the present invention, the computer system 100 includes a Sun Microsystems computer utilizing a SPARC microprocessor available from several vendors (including Sun Microsystems, Inc., of Santa Clara, Calif.). Those with ordinary skill in the art understand, however, that any type of computer system may be utilized to embody the present invention, including those made by Hewlett Packard of Palo Alto, Calif., and IBM-compatible personal computers utilizing Intel microprocessor, which are available from several vendors (including IBM of Armonk, N.Y.). Also, instead of a single processor, two or more processors (whether on a single chip or on separate chips) can be utilized to provide speedup in operations. It is further envisioned that the processor 102 may be a complex instruction set computer (CISC) microprocessor, a reduced instruction set computing (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, a processor implementing a combination of instruction sets, and the like.

[0018] The network interface 118 provides communication capability with other computer systems on a same local network, on a different network connected via modems and the like to the present network, or to other computers across the Internet. In various embodiments of the present invention, the network interface 118 can be implemented utilizing technologies including, but not limited to, Ethernet, Fast Ethernet, wide-area network (WAN), leased line (such as T1, T3, optical carrier 3 (OC3), and the like), analog modem, digital subscriber line (DSL and its varieties such as high bit-rate DSL (HDSL), integrated services digital network DSL (IDSL), and the like), cellular, wireless networks (such as those implemented by utilizing the wireless application protocol (WAP)), time division multiplexing (TDM), universal serial bus (USB and its varieties such as USB II), asynchronous transfer mode (ATM), satellite, cable modem, and/or FireWire.

[0019] Moreover, the computer system 100 may utilize operating systems such as Solaris, Windows (and its varieties such as CE, NT, 2000, XP, ME, and the like), HPUX, IBM-AIX, PALM, UNIX, Berkeley software distribution (BSD) UNIX, Linux, Apple UNIX (AUX), Macintosh operating system (Mac OS) (including Mac OS X), and the like. Also, it is envisioned that in certain embodiments of the present invention, the computer system 100 is a general purpose computer capable of running any number of applications such as those available from companies including Oracle, Siebel, Unisys, Microsoft, and the like.

[0020]FIG. 2 illustrates an exemplary partial exploded view of a computer system 200 in accordance with an embodiment of the present invention. In an embodiment of the present invention, the computer system 200 may include the same or similar elements discussed with respect to the computer system 100 of FIG. 1. The computer system 200 includes a chassis (1), a side panel (2) for service and/or accessing the modules within the computer system 200, a module (3) (which may include, for example, memory chips and one or more CPUs), a modular bezel (4) (which may include a control panel assembly and a system identifier (ID)), a modular hard disk drive cage (5) (which may include a back plane and one or more hard disk drives), a housing (6) which may include a peripheral component interconnect (PCI) fan and a speaker (e.g., as a module), a modular PCI hold down device (7) which can hold down multiple PCI long and/or short cards, and a support bar (8) for securing installed components within the computer system 200.

[0021]FIG. 3 illustrates an exemplary top view of a side panel 300 in accordance with an embodiment of the present invention. In an embodiment of the present invention, the side panel 300 may be the same or similar to the side panel (2) discussed with respect to the computer system 200 of FIG. 2. The side panel 300 includes one or more openings 302 along a shape formed by deep drawn dimples, extrusions, protrusions, or combinations thereof (e.g., along 304, 306, and/or 308). In one embodiment of the present invention, at least a portion of the openings 302 my form a geometric shape such as a circle, a square, an ellipse, a hexagon, a rectangle, combinations thereof, or the like. The shape may be irregular in accordance with an embodiment of the present invention. In one embodiment of the present invention, the openings 302 may be about 5 mm apart. The side panel 300 may be constructed from material such as sheet metal, Aluminum, galvanize steel, alloys or combinations thereof, or the like.

[0022] The side panel 300 may further include one or more locking tabs (not shown), one or more dimples 310 (e.g., for assembly, ventilation, and/or gripping purposes), a handle 312 (e.g., for installation of the side panel 300 into a computer system, or removing the same), and one or more mounting openings 314 (e.g., for mounting a logo and/or securing the side panel 300 to a computer system). In one embodiment of the present invention, the openings 302, the locking tabs, the dimples 310, the handle 312, and/or the mounting openings 314 may be formed by a same stamping process utilized to form a shape on the side panel 300 (e.g., along 304, 306, and/or 308).

[0023] In accordance with an embodiment of the present invention, the openings 302 may be stamped into the side panel 300 prior to forming the shape on the side panel 300 (e.g., along 304, 306, and/or 308). In another embodiment of the present invention, the openings 302 may have a substantially straight edge along the curvature of the desired shape. In a further embodiment of the present invention, the remaining portion of the openings 302 (i.e., other than the substantially straight edge) may form any desired shape (such as the semi-circle shown in FIG. 3 or a logo). In yet another embodiment of the present invention, the substantially straight edge may have a curvature substantially parallel to the curvature of the desired shape, for example, to be stamped on the side panel 300. It is also envisioned that the curvature of the substantially straight edge may follow a different angle than the curvature of the desired shape, for example, to be stamped on the side panel 300, in a different embodiment of the present invention.

[0024]FIG. 4 illustrates an exemplary side view of a side panel 400 in accordance with an embodiment of the present invention. In an embodiment of the present invention, the side panel 400 may be the same or similar to the side panel 300 discussed with respect to FIG. 3. The side panel 400 includes the openings 302 along a shape formed by deep drawn dimples, extrusions, or combinations thereof (e.g., along 304, 306, and/or 308), one or more locking tabs 402, the dimples 310, the handle 312, and the mounting openings 314. In various embodiments of the present invention, the side panel 400 may be a computer access panel and/or sidewall of an electronic system.

[0025] It is envisioned that the provision of the openings 302 prior to forming the desired shape on the side panel 300 (e.g., along 304, 306, and/or 308) through a stamping process limits or avoids twisting and/or warping the flat sheet metal used during the sheet metal stamping process. It is envisioned that the provision of the openings 302 prior to stamping the desired shape is useful in embodiments that seek to form an irregular shape by, for example, deep draw dimple, extrusion, and/or protrusion stamping processes. The stamping may be performed by a press machine, and the like. In an embodiment of the present invention, the stamping process may be controlled by a computer system such as those discussed with respect to FIGS. 1 and 2.

[0026] In a further embodiment of the present invention, the flatness of the sheet metal being stamped may be maintained by provision of the openings 302, which in turn provides a relatively stronger structure. In various other embodiment of the present invention, the stamped side panel 300 may provide grooves, openings, or other guiding paths (or channels) for provision of airflow, for example, for cooling purposes (which may be supplemented by fans in an embodiment of the present invention).

[0027] The foregoing description has been directed to specific embodiments of the present invention. It will be apparent to those with ordinary skill in the art that modifications may be made to the described embodiments of the present invention, with the attainment of all or some of the advantages. For example, the techniques of the present invention may be utilized in panels for set-top boxes, blade computers, electronic gaming apparatus (such as those provided by Microsoft Corporation of Redmond, Wash. (e.g., XBOX game machine), Sony Corporation of Japan (e.g., PlayStation game machine), and the like. Also, the desired shape to be formed may be for decorative and/or industrial design purposes. Therefore, it is the object of the appended claims to cover all such variations and modifications as come within the spirit and scope of the invention. 

What is claimed is:
 1. A method of providing an irregular shape on a computer panel, the method comprising: creating a plurality of openings in the computer panel, the plurality of openings tracing a pattern that forms the irregular shape, each of the plurality of openings having a substantially straight edge adjacent to the pattern; and applying force onto the computer panel along the plurality of openings to provide the irregular shape, wherein the plurality of openings reduce warping and twisting of the computer panel during the application of force.
 2. The method of claim 1 wherein the shape is formed by one or more items selected from a group comprising an extrusion and a protrusion.
 3. The method of claim 1 wherein at least a portion of each of the plurality of openings have a geometric shape.
 4. The method of claim 3 wherein the geometric shape is selected from a group comprising a circle, a square, an ellipse, a hexagon, a rectangle, and combinations thereof.
 5. The method of claim 1 wherein the force is applied onto the computer panel at an equal distance from each of the plurality of openings.
 6. The method of claim 5 wherein the equal distance is about 5 mm.
 7. The method of claim 1 wherein the plurality of openings provide a thermal exchange medium for a computer system utilizing the computer panel.
 8. The method of claim 1 wherein the computer panel is constructed from material selected from a group comprising sheet metal, Aluminum, galvanize steel, and combinations thereof.
 9. The method of claim 1 wherein the application of force is performed by a device selected from a group comprising a press machine and a computer-controlled press machine.
 10. The method of claim 1 wherein the irregular shape forms an item selected from a group comprising a logo and a channel for airflow.
 11. The method of claim 1 wherein the substantially straight edge may have a curvature following a same curvature of the pattern.
 12. A computer system comprising: a computer chassis; a side panel attachably coupled to the computer chassis; and an irregular shape formed on the side panel, the side panel including a plurality of openings, the plurality of openings tracing a pattern that forms the irregular shape, each of the plurality of openings having a substantially straight edge adjacent to the pattern.
 13. The computer system of claim 12 further including one or more central processing units (CPUs), wherein the side panel provides access to the CPUs.
 14. The computer system of claim 13 wherein the plurality of openings guide airflow.
 15. The computer system of claim 13 wherein the CPUs are adjacent to a plurality of memory banks, each memory bank corresponding to one of the CPUs.
 16. The computer system of claim 12 further including a power supply and one or more peripheral component interconnect (PCI) devices.
 17. The computer system of claim 12 wherein the irregular shape forms an item selected from a group comprising a logo and a channel for airflow.
 18. The computer system of claim 12 wherein the computer system is selected from a group comprising a set-top box, a blade computer, and an electronic gaming apparatus.
 19. An article of manufacture for providing an irregular shape on a computer panel, the article comprising: a machine readable medium that provides instructions that, if executed by a machine, will cause the machine to perform operations including: creating a plurality of openings in the computer panel, the plurality of openings tracing a pattern that forms the irregular shape, each of the plurality of openings having a substantially straight edge adjacent to the pattern; and applying force onto the computer panel along the plurality of openings to provide the irregular shape.
 20. The article of claim 19 wherein the irregular shape forms an item selected from a group comprising a logo and a channel for airflow. 